Composite structure and method of forming thereof

ABSTRACT

A composite structure is provided. The composite structure includes a plurality of components coupled together forming a joint, wherein the plurality of components are oriented such that a gap is defined at least partially therebetween. A filler structure is positioned in the gap, and the filler structure includes a closed cell foam core.

BACKGROUND

The field of the present disclosure relates generally to compositestructures and, more specifically, to filler materials for compositestructures that facilitate restricting delamination of the compositestructure.

Cracking of integrally stiffened composite structures, especially inaerospace applications, often initiates in a radius filler (i.e.,noodle) located at an interface between a skin and integral stiffeningelements of the composite structures. At least some known radius fillersare formed at least partially from an amount of resin. Cracks in theresin may form during manufacture of the composite structures as aresult of improper tooling, improper handling of tools, and/or residualtensile strain. For example, residual tensile strain in compositestructures may form as a result of a mismatch between the coefficientsof thermal expansion creating a strain environment in the radius fillerthat exceeds the critical cracking strain of the resin. The geometry ofthe structure surrounding the radius filler creates a three-dimensionalconstraint to shrinkage upon cooling of the resin after it has beencured and hardened.

Exemplary radius filler materials include, but are not limited to,pre-impregnated (i.e., prepreg) composite materials (e.g., layeredstrips and/or rolled prepreg composite material), and/or pure resin. Inat least some known composite structures, crack propagation in theradius filler can cause delamination of the plies in adjacent laminatedjoints. More specifically, crack propagation in the radius filler mayinitiate degradation of the laminated joints. While limiting theformation of cracks in the radius filler would ensure the integrity ofthe laminated joints, preventing cracks from forming entirely isgenerally difficult, if not impossible. Moreover, the difficulty inlimiting crack formation in radius fillers increases as compositestructures are fabricated in increasingly large sizes. As such, there isa need for systems and methods that ensure cracks in a radius filler donot initiate degradation of laminated joints.

BRIEF DESCRIPTION

In one aspect, a composite structure is provided. The compositestructure includes a plurality of components coupled together forming ajoint, wherein the plurality of components are oriented such that a gapis defined at least partially therebetween. A filler structure ispositioned in the gap, and the filler structure includes a closed cellfoam core.

In another aspect, a method of forming a composite structure isprovided. The method includes coupling a plurality of componentstogether forming a joint, wherein the plurality of components areoriented to form a radius gap therebetween. The method also includesforming a filler structure that includes a closed cell foam core,positioning the filler structure in the radius gap, and applying atleast one of heat or pressure to the plurality of components and thefiller structure.

The features, functions, and advantages that have been discussed can beachieved independently in various implementations of the presentdisclosure or may be combined in yet other implementations furtherdetails of which can be seen with reference to the following descriptionand drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a flow diagram of an exemplary aircraft production and servicemethod.

FIG. 2 is a block diagram of an exemplary aircraft.

FIG. 3 is a schematic illustration of an exemplary composite structurethat may be used in the aircraft shown in FIG. 2.

FIG. 4 is an enlarged schematic illustration of the composite structureshown in FIG. 3 taken along Area 4.

FIG. 5 is an enlarged schematic illustration of the closed cell foamcore shown in FIG. 4.

FIG. 6 is a schematic flow diagram illustrating an exemplary sequence ofprocess steps of fabricating a closed cell foam core that may be used inthe composite structure shown in FIG. 3.

FIG. 7 is a schematic flow diagram illustrating an alternative sequenceof process steps of fabricating the closed cell foam core shown in FIG.6.

FIG. 8 is a flow diagram of an exemplary method of forming a compositestructure.

DETAILED DESCRIPTION

The implementations described herein relate to composite structuresincluding a radius filler structure that facilitates restrictingdelamination in radius gaps (i.e., noodle regions) in the compositestructures. In the exemplary implementation, the filler structureincludes a closed cell foam core. The closed cell foam core includes aplurality of core cells including side walls and void spaces defined bythe side walls. The closed cell foam core is fabricated from a materialthat absorbs strain energy by enabling the side walls to yieldplastically in response to hydrostatic tensile forces. Specifically, thefiller structure is positioned in the radius gap of the compositestructure, and the closed cell foam core has physical propertiesselected to ensure the structural integrity of the composite structureis substantially maintained during manufacture thereof. As such, thefiller structure described herein does not include resin such that crackpropagation in the resin cannot initiate degradation of the laminatedjoint.

Referring to the drawings, implementations of the disclosure may bedescribed in the context of an aircraft manufacturing and service method100 (shown in FIG. 1) and via an aircraft 102 (shown in FIG. 2). Duringpre-production, including specification and design 104 data of aircraft102 may be used during the manufacturing process and other materialsassociated with the airframe may be procured 106. During production,component and subassembly manufacturing 108 and system integration 110of aircraft 102 occurs, prior to aircraft 102 entering its certificationand delivery process 112. Upon successful satisfaction and completion ofairframe certification, aircraft 102 may be placed in service 114. Whilein service by a customer, aircraft 102 is scheduled for periodic,routine, and scheduled maintenance and service 116, including anymodification, reconfiguration, and/or refurbishment, for example. Inalternative implementations, manufacturing and service method 100 may beimplemented via vehicles other than an aircraft.

Each portion and process associated with aircraft manufacturing and/orservice 100 may be performed or completed by a system integrator, athird party, and/or an operator (e.g., a customer). For the purposes ofthis description, a system integrator may include without limitation anynumber of aircraft manufacturers and major-system subcontractors; athird party may include without limitation any number of venders,subcontractors, and suppliers; and an operator may be an airline,leasing company, military entity, service organization, and so on.

As shown in FIG. 2, aircraft 102 produced via method 100 may include anairframe 118 having a plurality of systems 120 and an interior 122.Examples of high-level systems 120 include one or more of a propulsionsystem 124, an electrical system 126, a hydraulic system 128, and/or anenvironmental system 130. Any number of other systems may be included.

Apparatus and methods embodied herein may be employed during any one ormore of the stages of method 100. For example, components orsubassemblies corresponding to component production process 108 may befabricated or manufactured in a manner similar to components orsubassemblies produced while aircraft 102 is in service. Also, one ormore apparatus implementations, method implementations, or a combinationthereof may be utilized during the production stages 108 and 110, forexample, by substantially expediting assembly of, and/or reducing thecost of assembly of aircraft 102. Similarly, one or more of apparatusimplementations, method implementations, or a combination thereof may beutilized while aircraft 102 is being serviced or maintained, forexample, during scheduled maintenance and service 116.

As used herein, the term “aircraft” may include, but is not limited toonly including, airplanes, unmanned aerial vehicles (UAVs), gliders,helicopters, and/or any other object that travels through airspace.Further, in an alternative implementation, the aircraft manufacturingand service method described herein may be used in any manufacturingand/or service operation.

FIG. 3 is a schematic illustration of an exemplary composite structure200 that may be used in aircraft 102 (shown in FIG. 2), and FIG. 4 is anenlarged schematic illustration composite structure 200 taken along Area4. In the exemplary implementation, composite structure 200 includes aplurality of components 204 coupled together to form a T-joint 206.Components 204 include a skin panel 208, a plank 210 coupled to skinpanel 208, a first stiffener 212 coupled to plank 210, and a secondstiffener 214 coupled to plank 210. Components 204 are oriented suchthat a radius gap 216 is defined between plank 210 and first and secondstiffeners 212 and 214. More specifically, radius gap 216 extends alonga length L of composite structure 200 and is defined at least partiallyby opposing complementary bent portions 218 of first and secondstiffeners 212 and 214. In an alternative implementation, first andsecond stiffeners 212 and 214 may be coupled directly to skin panel 208.Moreover, alternatively, components 204 may have any configuration suchthat a joint defines a radius gap therebetween.

Composite structure 200 also includes a filler structure 220 positionedin radius gap 216. Referring to FIG. 4, filler structure 220 includes aclosed cell foam core 222 including a plurality of core cells 224. Eachcore cell 224 includes side walls 226, and void spaces 228 defined byside walls 226 and substantially filled with air. As such, fillerstructure 220 does not include an amount of resin. Moreover, as will bedescribed in more detail below, closed cell foam core 222 is fabricatedfrom a material such that side walls 226 yield plastically in responseto hydrostatic tensile forces 230 applied to and by composite structure200. Specifically, void spaces 228 facilitate enabling closed cell foamcore 222 to absorb energy and facilitate defining a porosity withinclosed cell foam core 222. The porosity of closed cell foam core 222 isselected such that closed cell foam core 222 has a predetermined energyabsorbing capability and bulk compression stiffness. For example, in theexemplary implementation, closed cell foam core 222 includes a porositywithin a range defined between about 20 percent and about 40 percent byvolume of closed cell foam core 222.

Closed cell foam core 222 may be fabricated from any material thatenables composite structure 200 to function as described herein. Thematerial used to fabricate closed cell foam core 222 is selected basedon whether the material includes certain physical properties atpredetermined levels. Exemplary physical properties include, but are notlimited to, bulk modulus, surface energy, and coefficient of thermalexpansion. For example, the bulk modulus is selected to facilitatelimiting deformation of closed cell foam core 222 when compositestructure 200 is exposed to elevated pressures during manufacturethereof, the surface energy is selected such that closed cell foam core222 remains coupled to components 204, and the coefficient of thermalexpansion is selected such that the structural integrity of compositestructure 200 is substantially maintained when exposed to changingenvironmental conditions. In the exemplary implementation, closed cellfoam core 222 is fabricated from a silicone-based material such asRTV566 manufactured by Momentive Performance Materials Holdings, Inc. ofAlbany, N.Y.

FIG. 5 is an enlarged schematic illustration of closed cell foam core222. As will be described in more detail below, at least one of heat orpressure are applied to components 204 to facilitate forming compositestructure 200 (each shown in FIG. 3). In general, hydrostatic tensileforces 230 (shown in FIG. 4) are hydrostatic due to the inability offiller structure 220 to contract upon cooling from elevated temperaturesduring formation of composite structure 200. As such, side walls 226locally stretch (i.e., are unable to contract) at narrowed regions 227resulting in post-yield plastic deformation thereof. More specifically,side walls 226 are relatively thin membranes such that stretching sidewalls 226 is not hydrostatic. Rather, closed cell foam core 222 isfabricated from material that enables side walls 226 to locally yield atnarrowed regions 227 to facilitate strain energy absorption therein.

FIG. 6 is a schematic flow diagram illustrating an exemplary sequence232 of process steps of fabricating closed cell foam core 222, and FIG.7 is a schematic flow diagram illustrating an alternative sequence 234of process steps of fabricating closed cell foam core 222. In theexemplary implementation, closed cell foam core 222 is fabricated bypouring a quantity of liquefied closed cell foam material (not shown)into a mold 236. Mold 236 includes an interior cavity 238 that receivesthe quantity of closed cell foam material and that has a shapesubstantially similar to a final desired shape of closed cell foam core222. The quantity of closed cell foam material is then cured in a firstprocessing step 240 such that closed cell foam core 222 has across-sectional shape substantially similar to radius gap 216 when it isformed. Moreover, first processing step 240 facilitates forming voidspaces 228 in closed cell foam core 222. For example, first processingstep 240 facilitates forming void spaces 228 by at least one ofintroducing a blowing agent into the quantity of closed cell foammaterial, or by fabricating closed cell foam core 222 via condensationpolymerization. Exemplary blowing agents include either physical orchemical blowing agents such as, but not limited to, carbon dioxide,pentane, and carbonate materials.

Referring to FIG. 7, closed cell foam core 222 is fabricated by pouringa quantity of closed cell foam material into a mold 242. Mold 242includes an interior cavity 244 that receives the quantity of closedcell foam material and that has any shape that enables sequence 234 tofunction as described herein. For example, in the exemplaryimplementation, interior cavity 244 has a substantially rectangularcross-sectional shape. The quantity of closed cell foam material is thencured in first processing step 240, as described above, such that anintermediate closed cell foam core 246 is formed. A size of intermediateclosed cell foam core 246 is reduced in a second processing step 248,such as cutting, milling, or machining. As such, second processing step248 is implemented to form intermediate closed cell foam core 246 intoclosed cell foam core 222 having a cross-sectional shape substantiallysimilar to radius gap 216. Alternatively, a plurality of intermediateclosed cell foam cores 246 may be fabricated in mold 242, coupledtogether, and subsequently reduced in size via second processing step248 to form closed cell foam core 222. Moreover, alternatively, aplurality of closed cell foam cores 246 of varying shapes may befabricated and coupled together in a predetermined orientation to formclosed cell foam core 222.

FIG. 8 is a flow diagram of an exemplary method 300 of forming acomposite structure, such as composite structure 200. Method 300includes coupling 302 components 204 together to form T-joint 206,wherein components 204 are oriented to form radius gap 216 therebetween.A filler structure 220 is formed 304 that includes closed cell foam core222. Method 300 also includes positioning 306 filler structure 220 inradius gap 216, and applying 308 at least one of heat or pressure tocomponents 204 and filler structure 220. The heat and/or pressure may beapplied via a vacuum bagging process, and/or composite structure 200 maybe placed in an autoclave (not shown).

In some implementations, forming 304 filler structure 220 includespouring a quantity of closed cell foam material into mold 236 having across-sectional shape substantially similar to a cross-sectional shapeof radius gap 216, and curing the quantity of closed cell foam materialin mold 236. Alternatively, forming 304 includes pouring a quantity ofclosed cell foam material into mold 242, curing the quantity of closedcell foam material in mold 242 to form intermediate closed cell foamcore 246, and forming intermediate closed cell foam core 246 such thatfiller structure 220 has a cross-sectional shape substantially similarto a cross-sectional shape of radius gap 216. Forming intermediateclosed cell foam core 246 includes at least one of cutting, milling, ormachining intermediate closed cell foam core 246.

Forming 304 filler structure 220 also includes fabricating closed cellfoam core 222 from a closed cell foam material having a bulk modulusthat facilitates limiting deformation of filler structure 220 when thepressure is applied 308, and fabricating closed cell foam core 222 froma silicone-based material. In one implementation, forming 304 fillerstructure 220 includes forming closed cell foam core 222 including sidewalls 226 configured to yield plastically in response to hydrostatictensile forces 230, and forming void spaces 228 defined by side walls226. The void spaces 228 are substantially filled with air.

In some implementations, forming 304 filler structure 220 includesforming closed cell foam core 222 including a porosity within a rangedefined between about 20 percent and about 40 percent by volume ofclosed cell foam core, and forming 304 filler structure 220 that doesnot include an amount of resin.

The implementations described herein relate to filler structures thatfacilitate restricting delamination of a composite structure frominitiating in a noodle region of the composite structure. The fillerstructure is fabricated from a closed cell foam core that includes sidewalls that yield plastically in response to hydrostatic tensile forces.For example, the side walls yield when the hydrostatic tensile forcesare applied during manufacture of the composite structure, but thefiller structure has a bulk modulus that facilitates limitingdeformation of the closed cell foam core and maintaining a desired shapeof the composite structure at increased pressures. Moreover, the fillerstructure does not include an amount of resin such that strain in thenoodle region is absorbed by the closed cell foam core, and such thatdelamination caused by crack propagation in the resin is eliminated.

This written description uses examples to disclose variousimplementations, including the best mode, and also to enable any personskilled in the art to practice the various implementations, includingmaking and using any devices or systems and performing any incorporatedmethods. The patentable scope of the disclosure is defined by theclaims, and may include other examples that occur to those skilled inthe art. Such other examples are intended to be within the scope of theclaims if they have structural elements that do not differ from theliteral language of the claims, or if they include equivalent structuralelements with insubstantial differences from the literal language of theclaims.

1-10. (canceled)
 11. A method of forming a composite structure, saidmethod comprising: coupling a plurality of components together forming ajoint, wherein the plurality of components are oriented to form a radiusgap therebetween; forming a filler structure that includes a closed cellfoam core; positioning the filler structure in the radius gap; andapplying at least one of heat or pressure to the plurality of componentsand the filler structure.
 12. The method in accordance with claim 11,wherein forming a filler structure comprises: pouring a quantity ofclosed cell foam material into a mold having a cross-sectional shapesubstantially similar to a cross-sectional shape of the radius gap; andcuring the quantity of closed cell foam material in the mold.
 13. Themethod in accordance with claim 11, wherein forming a filler structurecomprises: pouring a quantity of closed cell foam material into a mold;curing the quantity of closed cell foam material in the mold to form anintermediate closed cell foam core; and forming the intermediate closedcell foam core such that the filler structure has a cross-sectionalshape substantially similar to a cross-sectional shape of the radiusgap.
 14. The method in accordance with claim 13, wherein forming theintermediate closed cell foam core comprises at least one of cutting,milling, or machining the intermediate closed cell foam core.
 15. Themethod in accordance with claim 11, wherein forming a filler structurecomprises fabricating the closed cell foam core from a closed cell foammaterial having a bulk modulus that facilitates limiting deformation ofthe filler structure when the pressure is applied.
 16. The method inaccordance with claim 11, wherein forming a filler structure comprisesfabricating the closed cell foam core from a silicone-based material.17. The method in accordance with claim 11, wherein forming a fillerstructure comprises forming the closed cell foam core including sidewalls configured to yield plastically in response to hydrostatic tensileforces.
 18. The method in accordance with claim 17, wherein forming theclosed cell foam core comprises forming void spaces defined by the sidewalls, the void spaces substantially filled with air.
 19. The method inaccordance with claim 11, wherein forming a filler structure comprisesforming the closed cell foam core including a porosity within a rangedefined between about 20 percent and about 40 percent by volume of theclosed cell foam core.
 20. The method in accordance with claim 11,wherein forming a filler structure comprises forming the fillerstructure that does not include resin.
 21. The method in accordance withclaim 12 further comprising introducing a blowing agent into thequantity of closed cell foam material in the mold.
 22. The method inaccordance with claim 13 further comprising introducing a blowing agentinto the quantity of closed cell foam material in the mold.
 23. Themethod in accordance with claim 11, wherein forming a filler structurecomprises forming the closed cell foam core via a condensationpolymerization reaction.
 24. The method in accordance with claim 11,wherein applying at least one of heat or pressure comprises applying atleast one of the heat or the pressure via a vacuum bagging process. 25.The method in accordance with claim 11, wherein applying at least one ofheat or pressure comprises applying at least one of the heat or thepressure in an autoclave.